Gaps between prepreg tapes, which occur when prepreg tapes are placed automatically, cause concave deformation of the laminate during consolidation, which degrades the quality of the cured laminate. However, this in-situ concave deformation has never been measured. This study measures consolidation deformation of a cross-ply thermosetting composite laminate containing gaps of various widths at the middle layer. A unique fiber-optic-based shape sensor is used for the in-situ deformation monitoring and the deformation during autoclave pressurization and heating is presented. The results indicate that the deformation phenomenon depends on whether the upper bagging-side layer bridging the gap contacts the tool-side layer below the gap as it sinks into the gap during consolidation. The consolidation process reveals when the gap width is narrow, the fibers and the resin from the prepreg layer flow into the gap and displace upwards the sunken upper layer, partially reducing the concave deformation. One attempt to suppress gap-induced deformation is also made by using a curing condition inspired by the observation and understanding of this deformation mechanism.

自动放置预浸料带时，预浸料带之间会出现间隙，导致层压板在固结过程中发生凹形变形，从而降低固化层压板的质量。然而，这种原位凹形变形从未被测量过。本研究测量了中间层含有不同宽度间隙的交叉层热固性复合材料层压板的固结变形。采用独特的基于光纤的形状传感器进行原位变形监测，并给出了高压釜加压和加热过程中的变形情况。结果表明，变形现象取决于桥接间隙的上装袋侧层在固结过程中沉入间隙时是否与间隙下方的工具侧层接触。固结过程表明，当间隙宽度较窄时，来自预浸料层的纤维和树脂流入间隙并向上移动凹陷的上层，部分减少了凹形变形。受对这种变形机制的观察和理解的启发，还通过使用固化条件来尝试抑制间隙引起的变形。